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Journal of Engineering Science and Technology
Vol. 10, No. 4 (2015) 496 - 508
© School of Engineering, Taylor’s University
INFLUENCE OF KENAF AND POLYPROPYLENE FIBRES ON
MECHANICAL AND DURABILITY PROPERTIES OF FIBRE
REINFORCED LIGHTWEIGHT FOAMED CONCRETE
H. AWANG*, M. H. AHMAD, M. Z. Al-MULALI
School of Housing, Building and Planning,
Universiti Sains Malaysia, 11800 Minden, Penang, Malaysia
*Corresponding Author: [email protected]
Abstract
This paper investigates the mechanical and durability properties of lightweight
foamed concrete (LFC) with the inclusion of kenaf and polypropylene fibres. A
density of 1000kg/m3 foamed concrete was used for all the tested specimens.
The ratio of cement, sand and water used was 1:1.5:0.45. Polypropylene and
kenaf fibres were used as additives at 0.25% and 0.4% by volume of the total
mix. A 30% cement replacement by fly ash was used with each type of additive.
All the experiments were set up in accordance with International standard
methods of testing. Scanning electron microscopy (SEM) analysis is included to
have a better view of the concrete behavior with fibre inclusions. In reference to
the analysis and discussion, the types of fibre used were proven to have a lesser
contribution towards compressive strength or might even have reduced the
result. However, the integration of fly ash enhanced the compressive strength.
In addition, a higher percentage of fiber inclusions had been recorded to have a
positive contribution towards flexural, tensile spiltting and shrinkage properties
of LFC.
Keywords: Foamed concrete, Kenaf, Polypropylene, Mechanical, Durability.
1. Introduction
Different than conventional concrete, lightweight foamed concrete (LFC) is a
combination of cement, sand, water and foams. The difference between normal
496
Influence of Kenaf and Polypropylene Fibres on Mechanical and Durability . . . . 497
concrete and LFC from a materials perspective is there are no coarse aggregates
making LFC a lighter product. LFC consists of entrapped bubbles acting as
aggregate thus making it a better product in terms of workability, thermal
properties, concrete flow-ability leading to a lighter product. All these kinds of
advantages had made LFC becoming a better building material to create better
products with its wide flexibility. However, LFC has been detected to have some
disadvantages despite its numerous advantages. One of the main weaknesses of
LFC is its shrinkage due to its higher cement content and the low elastic modulus
of the aggregate [1-3]. Apart of being relatively lighter than the normal concrete,
the density varies from 300 kg/m3 to 1800 kg/m3 which set its limitation to bear a
certain level of loads only.
Despite all that, there have been numerous studies focusing on lightweight
foamed concrete with various types of additions and replacements to enhance its
durability and mechanical properties. By far, the trend of fibre inclusion in
lightweight foamed concrete has been a popular approach to encounter certain
problems regarding its mechanical and durability properties especially its drying
shrinkage. Inclusions of low volumetric short fibres have been proven to reduce the
impacts of early age shrinkage [4].
Both synthetic and natural resource fibres have its advantages in the matrix
proportioning of cement composites. Synthetic fibres are man-made fibres from
research and development of textile industries. It was first reported to be a component
of construction materials in 1965. The types of fibres used in Portland cement
concrete include: acrylic, aramid, carbon, nylon, polyester, polyethylene and
polypropylene. Thus, the use of synthetic fibre reinforced concrete currently exists
worldwide due to its promising feature of optimising durability and mechanical
properties of concrete. Moreover, it is proven that synthetic fibres helped to improve
the post peak ductility performance, pre-crack tensile strength, and impact strength
and eliminate temperature and shrinkage cracks [5].
In comparison with synthetic fibres, natural fibres are believed to be more
environmental friendly. That is why they are currently receiving a lot of attention for
replacing synthetic fibres [6]. It has been stated that natural fibres have many
advantages such as low density, recyclable and biodegradable [7]. Even if the
compressive and tensile strength of natural fibre concretes are slightly lower than the
control concrete mix, their deformation behavior shows improvement in ductility and
reduced shrinkage [8]. Besides that, natural fibre exhibits many advantageous
properties and offer significant reduction in the cost and also associated benefits with
processing in comparison to synthetic fibre [9, 10].
This study is an attempt to study the effect of both synthetic and natural fibres
when included as an additive on the properties of foamed concrete. The properties
tested are compressive strength, flexural strength, tensile splitting strength, water
absorption and drying shrinkage. In addition, it will investigate the effect of fly ash
addision on the mentioned properties of fibrous foamed concrete mixtures.
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H. Awang et al.
2. Materials
The type of cement used was Ordinary Portland Cement. As for the foam, a portable
foaming generator is used to fabricate practically stable foam purchased from a
Malaysian manufacturer (www.portafoam.com). A protein based foaming agent
namely, Noraite PA-1 was chosen to be used in this study due to its stable and smaller
bubbles and its stronger bonding structure of the bubbles in comparison to the
synthetic based surfactant [11]. The weight of the foam used in this investigation
varies in the range of 60-80gram/litre. Class F fly ash was used to replace the cement.
As for the fibres used, polypropylene fibre was purchased from Timuran Engineering
SDN BHD and the raw kenaf fibre was obtained from the state of Kelantan. The
properties for all the materials used are listed in detail in Tables 1 to 4.
Table 1. Chemical Composition of Ordinary Portland Cement.
Constituent
Ordinary Portland cement % by Weight
Lime (CaO)
Silica (SiO2)
Alumina (Al2O3)
Iron Oxide (Fe2O3)
Magnesia (MgO)
Sulphur Trioxide (SO3)
N2O
Loss of Ignition
Lime saturation factor
C3S
C2S
C3A
C4AF
64.64
21.28
5.60
3.36
2.06
2.14
0.05
0.64
0.92
52.82
21.45
9.16
10.2
Table 2. Properties of Fly Ash Class F.
Properties
Silicon dioxide (SiO2) plus aluminum oxide (Al2O3) plus iron
oxide (Fe2O3), min, %
Sulfur trioxide (SO3), max, %
Moisture Content, max, %
Loss on ignition, max, %
Percentage (%)
70
5
3
6
Table 3. Characteristics of Kenaf Fibre [12].
Cellulose (%)
45-57
Hemicellulose (%)
Fibre length
Lignin (wt. %)
Pectin (wt %)
Tensile strength (MPa)
Young’s Modulus (GPa)
Elongation at break (%)
21.5
19mm
8-13
3-5
930
53
1.6
Table 4. Characteristics of Polypropylene Fibre.
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Influence of Kenaf and Polypropylene Fibres on Mechanical and Durability . . . . 499
Composition
Configuration
Fibre length
Specific gravity
Melting point
Tensile strength
Thermal Conductivity
Electrical Conductivity
Absorption
Modulus of Elasticity
100% Polypropylene fibre
Fibrillated/Multi-Filament
19mm
0.9
1600C - 1700C
45-60 ksi (0.31 – 0.42 kN/mm2)
Low
Low
None
0.5 X 10 ksi (3.5kN/mm2)
3. Experimental Programme
There are two main experimental programmes in this research. The first part is the
mechanical properties which consist of three destructive tests namely compressive
strength, flexural strength and tensile splitting strength. The second part focuses on
the durability properties which consist of three tests which are water absorption,
drying shrinkage and scanning electron microscopy (SEM). Each test, the result is the
average of 3 specimens. A total number of 9 mixes including the control sample had
been prepared as been outlined in Table 5. The compressive strength test was
conducted using Autotest 3000 BS/ELE Compression Testing (Digital) Machine. The
test procedure was according to BS 1881: Part 116: 1983 [13] using a specimen size
of 100mm x 100mm x 100mm. The result was taken at 90th day of age. As for the
flexural strength test, it was conducted according to BS EN 1521:1997 [14]. The
specimen size is 100mm x 100mm x 500mm with the result taken at the 60th day of
age. All the procedures and specimens tested in the tensile splitting test were covered
up to the 28th day of age by referring to the ASTM C496 [15]. The specimen size used
was 100mm x 200mm. Last but not least, the test for drying shrinkage was conducted
according to BS 6073-1 [16].
Table 5 describes in detail the mix design used in this research. There are two
main lightweight foam concrete mixes prepared one with polypropylene and the other
was prepared with kenaf fibre as an inclusion. Essentially, the proportion of mortar
was cement, sand and water in the ratio of 1:1.5:0.45. Two percentages of fibre were
used; 0.25% and 0.4% out of the total volume of the mix. Kenaf fibres were treated
with 0.1mol NaOH for a night before being included into the mix to avoid any
degradation of fibres. With theoretical and practical experience in pilot studies, 30%
of class F fly ash was added in certain mixes as a cement replacement. In this case, the
inclusion of fly ash is considered as a secondary measure to encounter low
compressive strength when including fibres in concrete. The pozzolanic effect due to
the addition of fly ash has been proven to have greater strength as time increases
because of its continuing reaction with free limes.
Slump test was carried out for each mix design according to the standards for
lightweight foam concrete. The slump reading was taken within the range of 24-27cm.
The slurry mortar was then mixed with the foaming agent, Noraite PA-1 (protein
based) with the variation of foam weight 60-80 gram/litre. The total quantity of foam
added into each mix is different, depending on the targeted wet density of the
concrete. Target dry and wet densities are 1000kg/m3 and 1130kg/m3 correspondingly.
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All the mixes were left to dry in moulds in laboratory standard temperatures with no
rapid air flow for approximately 12 hours. After the de-moulding process, all the
specimens were sealed cured with plastic sheets (PSC) until a day before testing. The
specimens for compressive, flexural and tensile splitting tests were then oven dried for
a night and then tested. As for drying shrinkage specimens, it is left uncured in normal
air room temperature and tested in accordance with the days of test.
Table 5. Design Mix Proportion of Nine (9) Series of Fibre Reinforced LWC.
Sample
Normal foamed concrete
(control)
0.25% Polypropylene fibre
foam concrete
0.40% Polypropylene fibre
foam concrete
0.25% Polypropylene fibre
foam concrete with 30% fly
ash cement replacement
0.40% Polypropylene fibre
foam concrete with 30% fly
ash cement replacement
0.25% Kenaf fibre foam
concrete
0.40% Kenaf fibre foam
concrete
0.25% Kenaf fibre foam
concrete with 30% fly ash
cement replacement
0.40% Kenaf fibre foam
concrete with 30% fly ash
cement replacement
Sample
code
NF
PF25
PF40
Slump
Test
(mm)
Composition of mixture
Cement
(kg)
Fly
Ash
(kg)
Sand
(kg)
Water
(kg)
29.59
-
44.38
12.29
29.59
-
44.38
12.05
29.59
-
44.38
11.25
20.71
8.88
44.38
10.18
20.71
8.88
44.38
11.13
29.59
-
44.38
11.31
29.59
-
44.38
12.66
20.71
8.88
44.38
11.26
20.71
8.88
44.38
12.30
25
25
24
25
PFA25
24
PFA40
KF25
KF40
25
24
25
KFA25
25
KFA40
4. Analysis and Discussion
Figures 1 and 2 present the scanning electron microscopy (SEM) picture at 1000X
magnification for both kenaf and polypropylene fibres, correspondingly. Both pictures
show good adhesion between the fibres and the concrete matrix at the interfacial zone.
The bonding between fibres and the cement matrix is a crucial aspect governing the
performance of concrete properties. This bonding behavior led to a significant
increase of the pull-out load properties [17-20]. Thus, a good choice of fibre and
matrix proportion needs to be well studied to enhance the properties of concrete.
In regards to water requirements, water demand was changed for every mix to
achieve the slump range needed. However, it is obvious from Table 5, that kenaf fibre
LFC mixes demanded more water than the corresponding mixes with the
polypropolene reinforced LFC mixes due to the porous nature of the kenaf fibres.
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Fig. 1. SEM Magnification at 1000x of Kenaf Fibre Reinforced LFC.
Fig. 2. SEM Magnification at 1000x of Polypropylene Fiber Reinforced LFC.
4.1. Compressive strength
The results of compressive strength for kenaf and polypropylene fibre reinforced LFC
is shown in Fig. 3. The figure shows that there is an improvement of strength from
day 7 to 90 days of age. At the early age of test, all of the specimens with fibre
inclusion recorded a lower strength compared to the control mix. But specimens at 60
and 90 days of test started to show a positive enhancement of strength. There has not
been much difference between kenaf and polypropylene fibre in contribution to
compressive strength. The highest strength increment can be seen in the mixes with
fly ash inclusions which are PFA25, PFA40, KFA25 and KFA40. However, the
increase recorded was not more than 1% in comparison to the control mix. Both kenaf
and polypropylene fibre specimens were recorded to reach the same level of strength
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H. Awang et al.
as the control specimens. However, polypropylene fibre foamad concrete mixes
obtained higher compressive strengths than the Kenaf fibre mixes at all testing ages.
The inclusion of fibre is known to decrease the average compressive strength of
concrete [5, 21-22]. This is due to the problem of increasing water demand to reach
good workability thus lessening the concrete average compressive strength. This
theory can be applied to the hydrophilic type of fibres which tend to absorb water.
Both types of fibres show no big difference in increments of compressive strength
either in terms of fibre amount nor the type of fibre [23]. However, the compressive
strength of specimens increases with time by the replacement of cement by fly ash.
The ball bearing effect of the fine fly ash particles as shown in Fig. 4 creates a
lubricating effect. It lessens the water demand and increases the workability. In
addition, the pozzolan effect of fly ash has the ability to combine with the free lime in
concrete after the early stage of hardened state.
Fig. 3. Kenaf and Polypropylene Fibre Concrete Compressive Strength.
Fig. 4. Spherical Shape of Fly Ash Creating the Ball Bearing Effect.
4.2. Flexural strength
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Figure 5 presents the results of flexural strength of kenaf and polypropylene
reinforced LFC specimens. It can be drawn that both synthetic and natural fibres
contribute to flexural strength. All of the specimens were observed to have the
tendency to increase according to age. All the other specimens illustrated higher
results compared to the control specimens. The kenaf fibre reinforced LFC seemed to
have a lower average flexural strength at the early age in comparison to the
polypropylene fibre reinforced LFC. However, at the 60 days of age, the strength of
kenaf fibre LFC gradually increased. It can be drawn that the higher percentage of
fibre inclusion contributes more to the result of flexural strength. The average of
strength increase for kenaf and polypropylene fibre reinforced LFC as compared to
the control mix is 33.9% and 29.4% respectively. The analysis has shown that the
inclusion of these two fibres contributed to peak flexural strength achieved by the
specimens before reaching failure. Specimens without fibre inclusion had shown an
immediate failure by breaking into two parts after the peak flexural strength had been
reached. As shown in Fig. 6, the red arrows had shown, fibre that acts to prevent
micro-cracks propagation. As reported by Elsaid [24], when the concrete cracks, the
fibre prevents the micro-cracks from spreading and breaking into two parts.
Fig. 5. Kenaf and Polypropylene Fibre Concrete Flexural Strength.
Fig. 6. Fibres Preventing Micro-Crack Propogation.
4.3. Tensile splitting strength
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Figure 7 shows the results of the tensile splitting strength test. The graph shows that
the control mix resulted in a lower strength than all of the other specimens. Both
polypropylene and kenaf showed encouraging results but the highest result among all
is polypropylene fibre reinforced LFC. The specimens with 0.4% fibre and a 30% fly
ash cement replacement resulted in the highest strength. PFA40 and KFA40 resulted
in 0.897 and 0.866 N/mm2 respectively. This is 23.1% and 20.4% higher than the
control specimen.
Fig. 7. Kenaf and Polypropylene Fibre Concrete Tensile Splitting Strength.
Obviously, polypropylene reinforced LFC resulted in a better tensile splitting
strength compared to kenaf fibre reinforced LFC. Fibre helps to carry the load
through shear stress at the interface thus increasing the tensile split strength of the
LFC. However, this kind of attributes requires a good bonding between fibre and
matrix. Type of fibre is also one factor that needs to be analysed in order to have a
better result in tensile strength. Otherwise, fibre might suffer in rupturing and pullout problem which is typical for fibre reinforced concrete. In addition, the pattern
can be seen that specimens with fly ash and the most fibre inclusion achieved the
highest result. Fly ash can also be stated to have a contribution towards tensile
splitting strength of LFC. The pozzolan effect of fly ash gets the filling rate of
concrete to increase which makes a more impermeable and dense structure. In this
case, fly ash can be classified as the main driving force of tensile strength
enhancement since the same amount of fibre without fly ash specimen resulted in
obviously lower result.
4.4. Water absorption
The percentage rate of water absorption for kenaf and polypropylene fibre reinforced
LFC is presented in Fig. 8. It can be drawn that the lowest result in the rate of water
absorption is illustrated by polypropylene. This is followed by the kenaf fibre LFC
and the control specimen. The pattern of adding fly ash into mixes once again shows a
positive result by which it decreases the percentage rate of water absorption. KF25
and KF40 resulted in the highest rate of water absorption while PFA25 and PFA40
got the lowest percentage among all specimens. Polypropylene is known to be a
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Influence of Kenaf and Polypropylene Fibres on Mechanical and Durability . . . . 505
hydrophobic type of fibre which repels water absorption. But kenaf fibre absorbs
more water compared to the polypropylene fibre due to its surface morphology that
consists of more pores compared to polypropylene fibre. However, the difference in
the results of both kenaf and polypropylene is not significant. Kenaf fibre had been
treated with NaOH for it to be blended well in the cement matrix. This creates a more
alkaline field to avoid degradation of the fibres. The degradation of natural fibre could
lead to weak tensile fibres.
Fig. 8. Kenaf and Polypropylene Fibre Concrete Water Absorption.
4.5. Drying shrinkage
By referring to Fig. 9, the highest shrinkage values is obtained by the control mix
(NF) with 11.8%. It is followed by KF25 with 6.5% of shrinkage from the day of
casting. PFA40 states almost 59% of the shrinkage difference outperforming the
control mix even though it has the most shrinkage percentage among all fibrous
specimens. Both kenaf and polypropylene resulted in encouraging results and there
is no much difference in shrinkage percentage between these two fibre reinforced
LFC. The lowest drying shrinkage has been obtained by the polypropylene
specimen with the most percentage of fibre inclusion and fly ash inclusion with a
shrinkage reading of 4.8% at 180 days of age. This has shown that the value of
adding more fibre and fly ash contributes to better shrinkage prevention. Although
the shrinkage readings of fibrous foamed concrete mixes are less than the control
mix, the shrinkage readings are higher than the range specified by Valore [25] for
foamed concrete mixes 0.06-0.3%.
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Fig. 9. Drying Shrinkage of Kenaf And Polypropylene LFC by Days of Test.
It is supported by Roohollah et al. [22] in which he stated that the increase in fibre
percentage inclusion reduces the drying shrinkage of concrete. Fiber inclusion for
reducing the shrinkage percentage has been proven to be a tremendous approach. For
LFC, no presence of aggregates makes it shrink even more compared to normal
concrete. But with the existence of fibre, it acts as the aggregate with the ability of
void filling thus lessening the shrinkage percentage of LFC. The effectiveness of fibre
to reduce shrinkage decreases the cracking percentage of concrete. In addition, fiber
has the ability to bridge a crack after the first crack occurs, giving some warning time
and preventing it from opening.
5. Conclusions
According to the analysis made, it can be concluded that the fibre inclusion decreases
workability, thus, demanding more water to achieve the required 24-27cm slump.The
addition of water is much related to the reduction in compressive strength of concrete.
Hence, the approach of fly ash inclusion has been a great contribution to overcome
strength reduction of fibrous LFC type and amount of fibre inclusion is one factor that
needs to be well studied. Some types of fibres do not have good quality in terms of
matrix and fibre bonding which could lead to certain properties of failure. 0.4%
percentage of fibre inclusions has been proven to have better properties in this
research. Foamed concrete mixes with 0.4% of polypropylene fibre with 30% fly ash
replacement of cement obtained higher compressive strength, higher flexural strength,
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Influence of Kenaf and Polypropylene Fibres on Mechanical and Durability . . . . 507
higher tensile splitting strength, lower water absorption and lower shrinkage reading
than the corresponding mix with kenaf fibres. Moreover, mixes containing synthetic
and natural fibres obtained higher compressive strength, tensile splitting strength,
flexural strength, lower absorption and lower shrinkage readings than the control mix.
However, extra research needs to be done in terms of enhancing the fibre properties
especially for the natural sourced fibre.
Acknowledgement
The authors are thankful for the financial support in this research granted by
Universiti Sains Malaysia under USM RU Grant (Ref. No. 1001/ PPBGN/ 811234)
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